Tool with remote switch

ABSTRACT

A non-pneumatic system for use with a workpiece is described. A clamp assembly having a clamp pad is secured to the cabinet. An electrically operated tool is movably secured to the cabinet. The tool has a remote switch which when activated in turn activates the tool. A lever (e.g., a handle) is operatively coupled to the clamp assembly and the tool. When the lever is manually moved, the remote switch is activated and the clamp pad moves towards the work surface. Preferably, the tool also moves towards the work surface opening by manually moving the lever. For example, the tool utilized in this non-pneumatic system may be a drill or saw.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a divisional of application Ser. No. 11/210,588,filed 24 Aug. 2005, entitled “Non-Pneumatic Clamp and Drilling System,”and issued as U.S. Pat. No. 7,641,424 on Jan. 5, 2010, which claims thebenefit under 35 U.S.C. 119 (e) of U.S. Provisional Application No.60/603,976 filed on 24 Aug. 2004, entitled “Pocket Hole Boring Machine,”both of which are incorporated herein by reference.

FIELD OF THE INVENTION

The present subject matter relates generally to drilling, and, moreparticularly, to a one-step drilling system and methods of using same.

BACKGROUND OF THE INVENTION

There are many types of machines in use today for drilling holes such asdowel holes, pocket holes, and so forth, in various types of workpieces.Pocket hole wood joinery involves joining boards by inserting a fastenerat an angle through the edge of one board into the other. Such jointsare commonly used for face frames, cabinet boxes, leg-to-rail joinery inchairs and tables, and so forth. Drill guides, jigs, and pocket holeboring machines are used to drill the holes through which the fastenersor pocket screws are inserted into the adjoining workpiece.

Conventional devices utilize a two-step process to manually clamp andthen drill. Such a process is inconvenient and time-consuming.Additionally, such clamps do not readily accommodate common materialthicknesses. Other devices utilize a one-step process, but require anexpensive pneumatic air cylinder with a clamp pad. The use of pneumaticsfurther requires a source of air, i.e., an air compressor, which adds tothe inconvenience and expense.

For the reasons stated above, and for other reasons stated below whichwill become apparent to those skilled in the art upon reading andunderstanding the present specification, there is a need in the art foran improved drilling system.

BRIEF SUMMARY OF THE INVENTION

A non-pneumatic drilling system comprising a handle connected to anadjustable clamp and to a drill switch, wherein the adjustable clamp isnot in contact with a workpiece and the drill switch is off when thehandle is in a first position, further wherein the adjustable clamp isin contact with the workpiece and the drill switch is on when the handleis in a second position is described. In most embodiments, the drillswitch is turned on prior to the handle reaching the second position,i.e., at some point after the handle is moved away from the firstposition. In one embodiment the adjustable clamp is about 0.01 to 0.2inches above the workpiece when the handle is in the first position. Inone embodiment, the second position is lower in height than the firstposition, and the handle moves from the first position to the secondposition when manually pulled in a downwardly direction. The drillswitch is in electrical contact with a drill, and the drill andadjustable clamp start moving at about the same time as the handle isbeing moved from the first position to the second position, such that aworkpiece can be clamped and drilled in one step. In one embodiment, thedrill is secured at an angle of about 15 degrees to a work surface, onwhich the workpiece is placed.

In one embodiment, the adjustable clamp comprises a compression springin contact with a clamp pad, and the clamp pad remains stationary on theworkpiece as the compression spring applies increasing force. The systemis designed so that a drill bit, which is insertable into the drill,contacts the workpiece after the clamp pad contacts the workpiece. Theadjustable clamp is in contact with the workpiece and the drill bit isat its maximum depth within the workpiece when the handle is in a thirdposition, which, in one embodiment, is lower in height than the secondposition, such that the handle moves from the second position to thethird position when manually pulled in a downwardly direction.

In one embodiment the handle is located at an angle of about 45 degreesfrom the workpiece when in the third position. In one embodiment, theratio of movement between the adjustable clamp and drill is betweenabout 1:1 and about 1:10 as the handle moves from the first position tothe third position. In most embodiments, the handle is pivotallyconnected to a central axis rod via a bracket, the adjustable clamp ispivotally connected to the central axis rod via a linkage arm and thedrill is pivotally connected to the central axis rod with a connector.In one embodiment, the linkage arm is connected to the central axis rodwith a linkage bracket, and the linkage arm comprises first and secondlinkage arms, wherein the first linkage arm is pivotally connected tothe linkage bracket at one end and pivotally connected to the secondlinkage arm at an opposing end, and the second linkage arm is pivotallyconnected to the adjustable clamp.

In one embodiment, the system further comprises a clamping tower securedto the adjustable clamp and pivotally connected to the second linkagearm such that upward force from the first and second linkage arms istransferred to a downward clamping force on the adjustable clamp as thehandle is moved in a downwardly direction. In one embodiment, guide rodsconnected to the drill and to a guide block secured beneath the worksurface are used to guide the drill bit into the guide block and upthrough an opening in the work surface during drilling of the workpiece.

A pocket hole boring machine comprising a power source connected to acabinet, the cabinet having a work surface; a clamp assembly secured tothe cabinet on top of the work surface; a drill secured to the cabinetbeneath the work surface, the drill electrically connected to a remoteswitch and pivotally connected to the clamp assembly; and non-pneumaticmeans for simultaneously activating the remote switch and the clampassembly with a handle, wherein the handle, clamp assembly and drill areeach connected to a central axis rod is also provided. The machine canfurther include, in one embodiment, a fence secured to the cabinet. Thefence is used to support movable stops, such as flip-stops, although theinvention is not so limited. In one embodiment, the non-pneumatic meansfor activating the remote switch is provided by removing contact betweenthe linkage arm and a tab located in the switch to close the electricalcircuit when the handle is manually moved away from a first position. Inone embodiment, the clamp assembly is pivotally connected to the centralaxis rod with a linkage arm which extends beneath the work surface, andthe means for activating the clamp assembly is provided by pivoting thelinkage arm against a clamping tower secured to the clamping assemblywhen the handle is manually moved away from a first position. The clampassembly preferably contains a compression spring which continues toapply increasing force as the handle is moved from the first position tothe second position.

An adjustable clamp assembly for securing a workpiece to a work surfacecomprising a compression spring surrounding a spring rod, wherein theadjustable clamp assembly is adjustable in length and orientedsubstantially perpendicular to the workpiece with a linkage armconnected to the work surface is also provided. In one embodiment, thecompression spring can be preloaded by securing a clamp pad to thespring rod. In a particular embodiment, the spring rod has a threadedend and the compression spring is preloaded by threading the clamp padonto the spring rod. In one embodiment, the compression spring ispreloaded at least about 125 lb_(f). In one embodiment, the adjustableclamp assembly is adjustable in length with an adjusting knob securableto a fixed section, the fixed section pivotally connected to the linkagearm. In a particular embodiment, the fixed section has fixed sectionouter threads and the adjusting knob has adjusting knob inner threadssecurable to the fixed section outer threads. In one embodiment, theadjustable clamp assembly further comprises a locking knob to lock thefixed section and adjusting knob in place. The compression spring canprovide up to about 0.5 inches of displacement to the clamp assembly,such as up to about 0.25 inches. In one embodiment, the compressionspring provides up to about 300 lb_(f) of force to a workpiece.

Embodiments of the invention further include a method comprisingactivating an adjustable clamp assembly and a remote drill switchsubstantially simultaneously by pulling a handle connected to theadjustable clamp assembly and the remote drill switch in a downwardlydirection, wherein clamping and drilling are completed in one stepwithout the use of compressed air. In one embodiment, the method furthercomprises drilling a hole in a workpiece with a drill connected to theremote drill switch, the drill having a drill bit connected thereto. Inone embodiment, the method further comprises pushing the handle in anupwardly direction after the hole has been drilled. In most embodiments,the drill and adjustable clamp assembly start moving at about the sametime. The drill switch is in off when the handle is in a first position.The drill switch is on when the handle is in either a lower secondposition or an even lower third position.

In one embodiment, the handle is a lever and the user operates thedevice by first positioning the material to be drilled and then pullingthe lever forward. This motion activates the switch, which in turnactivates the drill motor and further throws or moves the clampassembly. The drill stroke is completed by continuing to pull on thelever and then returning the lever to its home position. Although thelever is operated manually, the automated features of the device allowsthe user to quickly drill holes, such as pocket holes.

Embodiments of the drilling systems and methods described herein allow auser, for the first time, to use a semi-automatic device to clampmaterial of variable dimensional thicknesses and drill holes, such aspocket holes, in one step without the use of a pneumatic clampingcylinder.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a simplified perspective view of a pocket hole drillingmachine with a portion of the cabinet cut away in one embodiment of thepresent invention.

FIG. 2 is a simplified perspective view of a switch mechanism of thepocket hole drilling machine of FIG. 1 in one embodiment of the presentinvention.

FIG. 3 is a simplified perspective view of an underside of a pocket holedrilling machine with a portion of the cabinet removed in one embodimentof the present invention.

FIG. 4 is a simplified perspective view of the underside of the pockethole drilling machine of FIG. 3 from a different perspective in oneembodiment of the present invention.

FIG. 5 is a cut-away side view of a clamp assembly, clamping tower,linkage arms and handle of the pocket hole drilling machine of FIG. 1 inone embodiment of the present invention.

FIG. 6, FIG. 7 and FIG. 8 are side views of the clamp assembly, clampingtower, linkage arms and handle, respectively, of FIG. 1 during variousstages of use; i.e., prior to clamping and drilling (FIG. 6), duringfirst contact of the clamp assembly with a workpiece (FIG. 7), and aftera pocket hole has been drilled (FIG. 8) in embodiments of the presentinvention.

FIG. 9 is a simplified perspective view of a pocket hole drillingmachine in one embodiment of the present invention.

DETAILED DESCRIPTION

In the following detailed description of embodiments of the invention,reference is made to the accompanying drawings that form a part hereof,and in which is shown by way of illustration specific preferredembodiments in which the subject matter may be practiced. Theseembodiments are described in sufficient detail to enable those skilledin the art to practice them, and it is to be understood that otherembodiments may be utilized and that mechanical, structural, electrical,and procedural changes may be made without departing from the spirit andscope of the present subject matter. The following detailed descriptionis, therefore, not to be taken in a limiting sense, and the scope ofembodiments of the present invention is defined only by the appendedclaims and their equivalents.

FIG. 1 shows one embodiment of a novel pocket hole boring machine 100.In this embodiment, the machine 100 comprises a cabinet 102 housing adrill 108 pivotally connected to an adjustable clamp, clamping cylinderor clamp assembly 110. The cabinet 102 (shown partially cut away inFIG. 1) comprises a work surface (i.e., worktable) 101, a back surface105 with a back surface opening 107, two side surfaces 111 (one shown)and a front surface 113. In some embodiments, the cabinet 102 furthercomprises legs. The worktable 101 has a top surface 104, a bottomsurface 103, and a drill bit opening 106. In this embodiment, themachine 100 further houses upper and lower linkage arms, 112 and 114,respectively, a fence 116 secured to top surface 104 and incommunication with one or more stops 118 to guide a workpiece (notshown). Although triangular stops are shown, in practice any suitabletype of stops 118 known in the art can be used. The fence 116 can besecured to the worktable 101 from the topside or underside and, in oneembodiment, is movable forwards or backwards to change the position of apocket hole from the edge of the workpiece.

The machine 100 further houses a central axis rod 119 connected to thetop surface 104 with a central axis rod bracket 121 and secured in placeto an opening in a central axis bracket 121 with a securing device 123,such as the nut shown in FIG. 1. A connector or connecting rod 120connects the drill 108 to the central axis rod 119 (shown in more detailin FIGS. 2 through 4). A guide block 126 is secured to the bottomsurface 103 of the worktable 101 by any suitable means, such as withthreaded screws from the top. Two guide rods 124 are removably securedinto guide rod openings in the guide block 126 in any suitable manner(e.g., set screws, threads, press fit, etc.) and are in substantiallyparallel alignment with a guide bushing 128 removably secured intobushing openings in the guide block 126 by any suitable means (e.g., setscrews, threads, press fit, etc.), although the invention is not solimited. In other embodiments, no guide bushing 128 is used. However,the guide bushing 128 is useful in supporting a drill bit 109 and thetwo guide rods 124 during drilling, keeping them in substantiallyparallel alignment and minimizing deflection of the drill bit 109 as itcontacts a workpiece.

The central axis rod 119 is in turn connected to the upper and lowerlinkage arms, 112 and 114, respectively, by a linkage arm bracket 125,which also extends beneath the worktable 101 (See FIG. 2). Morespecifically, in this embodiment, the linkage arm bracket 125 isconnected to a first end 127 of the lower linkage arm at pivot point “A”with a central axis/lower linkage pivot pin 129, while a second end 131of the lower linkage arm 114 is connected to a first end 132 of theupper linkage arm 112 at pivot point “B” with an upper linkage/lowerlinkage pivot pin 134. The central axis rod 119 is also connected to ahandle 136 via a handle bracket 137 as shown, the handle 136 also havinga hand grip 138 secured at its opposing end as shown. In the embodimentshown in the figures, the handle 136 is a lever pivotally connected viaa handle bracket 137 to the central axis rod 119, which serves as afulcrum. Although the handle 136 is shown as movable in a downwardlydirection to activate the clamp assembly 110 and switch (202) shown inFIG. 2, the invention is not so limited. In other embodiments, thehandle 136 may be a lever designed to move in an upwardly direction toactivate the components. In yet other embodiments, any other type ofsuitable handle 136 can be used. Although the connection between thehandle 136 and the handle bracket 137 is at an acute angle as shown,this is provided in order to orient the handle 136 at an appropriateangle to the user and not to provide a pivot point. In otherembodiments, there is no bracket 137 and the handle 136, having anysuitable bend, connects directly to and pivots on the central axis rod119. The clamp assembly 110 is connected to a second end 140 of theupper linkage arm 112 at pivot point “C” with a clamp/tower bracket 144and clamp assembly pivot pin 146. A clamping tower 142 is connected tothe upper linkage arm 112 with a clamping tower bracket 148 at pivotpoint “D” with a clamping tower pivot pin 150. A clamp assembly bracket152 also fixedly secures the clamp assembly 110 to the clamping tower142 below pivot point “D” as shown. Thus, the clamping tower 142 notonly secures the clamp assembly 110 in a fixed position during use, italso provides support for pivot point “D” with the upper linkage arm112. The clamping tower 142 therefore needs to be of a sufficient heightto not only be secured to the upper linkage arm 112 at pivot point “D”but to also provide means to fix the clamp assembly 110 in place duringuse, such as with the clamp assembly bracket 152 shown in FIG. 1.Although the clamping tower 142 is shown attached to the fence 116, suchas with a threaded bolt inserted from under the fence 116 (not shown),in other embodiments, the clamping tower 142 is located behind the fence116, and extends to the worktable 101.

The pivot points (A-D) allow the device to operate in one smooth andcontinuous manner to complete a drilling operation. Additionally, pivotpoint “C” allows the force provided by the clamp assembly 110 to besubstantially perpendicular to the top surface 104, thus minimizing theforce required to perform the operation. Pivot point “D” allows for thetransfer of force from an upward force provided by the upper and lowerlinkage arms, 112 and 114, to a downward clamping force as the handle136 is pulled.

The clamp assembly 110 is comprised of a compression spring 170, a clamppad 172, a clamp guide 174, an adjusting knob 176, a fixed section 178and a locking knob 180. In the embodiment shown in FIG. 1, both thelocking knob 180 and the adjusting knob 176 have a knurled outer surfacewhich provide a raised surface to improve gripping, although theinvention is not so limited. The fixed section 178 is connected to theclamp/tower bracket 144 by any suitable means, such as with a threadedconnection. The adjusting knob 176 is connectable to the fixed section178 on one end by any suitable means. In one embodiment, the adjustingknob 176 is slideable within the fixed section 178, similar to the typeof adjustment mechanism found on a microscope. In another embodiment,the adjusting knob 176 screws onto the fixed section 178 (such as withthreads 512 shown in FIG. 5). The adjusting knob 176 extends through theinside of the clamp guide 174 and also provides a housing or coveringfor the compression spring 170 on the other end (seen below the clampassembly bracket 152). The adjusting knob 176 is used to adjust theclamp assembly 110 for variations in material thicknesses of theworkpiece (not shown). In the embodiment, in which the adjusting knob176 and fixed section 178 are screwed together, adjusting knob innerthreads move up or down along outer threads of the fixed section as theadjusting knob 176 is turned• within the clamp guide 174. In mostembodiments, the workpiece must be at least about “⅜-inches” inthickness. Once the desired position is reached, the locking knob 180 isturned to lock the adjusting knob 176 into position, thus securing theclamp assembly 110 in place. The compression spring 170 provides desired“give” in the clamp assembly 110. Additional details about the clampassembly 110, including the compression spring 170, are discussed inFIG. 5.

In the embodiment shown in FIG. 1, a power source 152 (such as an ac/dccurrent) provides power for the electric box 153 via a power cord 155.The electric box 153 is in turn electrically connected via suitablewiring 303 (shown in FIG. 3) to a switch 202 (shown in FIG. 2). Theswitch 202 is in turn connected to the motor 160 via a motor wire 154.In other embodiments, the power source 152 is any other suitable sourceof power such as batteries, and the like, further including anyalternative source of renewable power. However, as it is desirable notto run the motor 160 continuously, means are preferably provided in thevarious embodiments to turn off the motor 160 in between drillingoperations, such as with the switch 202 discussed in FIG. 2.

The drill 108 comprises a motor 160, motor bracket 162, the guide rods124, drill bit 109, collet 164 and, preferably a stop collar 166 asshown in FIG. 1, although the invention is not so limited. It is alsopossible to complete the drilling operation without a stop collar 166(See, for example, FIG. 4). As shown in FIG. 1, the drill 108 does notrequire any type of handle as it is activated by the user pulling downon the handle 136, such as with the hand grip 138. The collet 164 issecured to the motor 160 in any suitable manner. In one embodiment, theconnection is a threaded connection. The drill bit 109 is secured to thecollet 164 in any suitable manner as is known in the art, such as with afriction connection, set screws and the like. The drill 108 is securedat an angle of about 15 degrees to a workpiece in order to drill pocketholes, although the invention is not so limited. The drill 108 can besecured at any desirable angle as needed to drill any other type ofhole. The motor 160 can provide any suitable amount of power. In oneembodiment, the motor 160 provides anywhere from ½ hp up to 1½ hp,although the invention is not so limited. In a particular embodiment, a¾ hp motor is used.

The guide rods 124 can extend any suitable distance into the guide block126 and, in one embodiment, extend about one (1) to three (3) inchesinto the guide block 126. Although two guide rods 124 are shown, inpractice any number of guide rods 124 can be used as long as theintended function is performed. The motor 160 is mounted to the motorbracket 162 in any suitable manner. In one embodiment, the connection isa threaded connection. The motor bracket 162 preferably has suitablebushings 163 (one shown) to enhance the sliding motion of the drill 108along the guide rods 124. In one embodiment, springs (not shown) arealso present on the guide rods 124 between the guide block 126 and thebushings 163 to help return the drill 108 to its initial position oncethe drilling is completed.

The motor 160 is designed to provide the requisite revolutions perminute (RPM) and torque required for a pocket hole drilling operation.Typically the RPM ranges from about 2200 to 2800 RPM and the torqueranges from about 50 to 75 in/lb_(f). It is also important that themotor 160 be small enough to fit into the cabinet 102 and be able toeasily move along the guide rods 124 in response to the hand grip 138(and hence the handle 136) being pulled down by the user. In aparticular embodiment, the motor is no greater than about nine (9)inches in length and no greater than about five (5) inches in diameter,although a larger motor 160 could be used, depending on the size of thecabinet 102. The motor 160 can be any suitable weight as long as it caneasily slide along the guide rods 124. In one embodiment, the motor isless than about eight (8) lbs, although the invention is not so limited.In a particular embodiment, the motor is about nine (9) inches inlength, about five (5) inches in diameter, providing about 2600 RPM andabout 65 in/lb_(f) of torque. In one embodiment, Groschopp, Inc., havingoffices in Sioux Center, Iowa, provides certain basic components for themotor 160, such as an armature, magnetic field, shaft, gears andbearings, as is known in the art, although such components are availablefrom any number of commercial suppliers. Other components such aswiring, brushes (to transfer current and create the rotation needed forgenerating the appropriate RPM's) and housing can also be purchasedcommercially or custom made for a particular application. The housingshould be designed so that the components are securely maintained in theproper position to allow the magnetic field to be substantiallyconcentric to the armature and shaft. Additional considerations for thehousing include providing proper air flow so the motor 160 does notoverheat.

In one embodiment, the drill 108 is a conventional handheld drill (suchas a Bosch drill made by the Bosch Power Tool Company having offices inChicago, Ill.) with appropriate modifications to change the drill 108from being activated by a trigger in the handle to being remotelycontrolled as described. In one embodiment, the drill 108 is controlledremotely with a wireless device. Alternatively, the drill can be lockedin the “on” position, although most drills are not designed forcontinuous operation and should be turned on and off as needed.Additional design considerations involve proper mounting of the drill108 to a bracket 162 and to the guide rods 124. In one embodiment aBosch Model 1005VSRK ⅜″ electric drill is used after appropriatemodifications have been made.

Referring to FIG. 2, the motor 160 (not shown) is activated by a switch202 secured to the bottom surface 103 with a bracket 310 (shown in FIG.3), although the invention is not so limited. The switch 202 can belocated in any suitable position and secured to the worktable 101 in anysuitable manner. In one embodiment, the switch 202 is an on/off switchthat is “off” only when the handle 136 is in its “home” or inactiveposition, i.e., the “up” position shown in FIGS. 1 and 6. Specifically,linkage arm bracket 125 extends down below the central axis rod 119,passes through an upper surface slot 204, and connects to the connectingrod 120 with a connecting rod bracket 206 below the top surface 104 ofthe worktable 101 as shown. The back surface opening 107 allows thecomponents to move freely in and out of the cabinet 102 as needed. Inthis embodiment, the switch 202 is activated by removing contact with atab 208, which is secured to the linkage arm bracket 125 as shown,although the invention is not so limited. Any suitable means can be usedto activate the switch 202, including providing means to contact theswitch 202 with a suitable device in order to activate it (versusremoving contact with a component, such as the tab 208, in order toactivate it). Basically, any device which allows the switch 202 tochange from having an open electrical circuit (no power) to a closedelectrical circuit (power) can be used.

In the embodiment shown in FIG. 2, the switch 202 is not depressed(closed electrical circuit) because there is no contact with the tab 208and therefore power is running to the motor 160 (not shown), causing themotor 160 to be on. The handle 136 is therefore not in its uppermost or“home” position. Conversely, when the switch 202 is in contact with,i.e., depressed by the tab 208, the motor 160 would be off. Again, thiswould occur when the handle 136 is in the uppermost “home” position (SeeFIG. 6). As shown in FIG. 3, suitable wiring 303 is provided as is knownin the art to connect the switch 202 to the electrical box 153. Suitablewiring 154 is also provided to connect the motor 160 to the electricalbox 153 as previously discussed. Any suitable type of switch 202 can beused. In one embodiment, the switch 202 is a spring loaded switch whichresponds to pressure and removal of pressure by the tab 208. See alsoFIG. 4 which provides another view of the various connections underneaththe worktable 101.

The various components of the pocket hole boring machine 100 can be madefrom any suitable materials and be of any suitable size and shape. Theupper and lower linkage arms, 112 and 114, respectively, are necessarilymade from materials having sufficient strength to transfer the requisiteforces across their length without any bending and flexing. In oneembodiment, these components are made from metal (e.g., steel oraluminum). Other materials, such as wood or plastic can be used, butwould likely require substantial thickness to have the requisitestrength. In one embodiment, the material is “ 3/16-inch” steel. In oneembodiment, the force transferred through these components is greaterthan about 200 lb_(f) up to about 300 lb_(f).

In one embodiment, the upper linkage arm 112 is about four (4) to seven(7) inches in length and the lower linkage arm 114 is about three (3) tofive (5) inches in length, although the invention is not so limited. Thelinkage arm bracket 125 can also be any suitable shape and size, and inone embodiment, the upper portion of the linkage arm bracket 125extending from the center axis rod 119 to the first end 127 of the lowerlinkage arm 114 is about one (1) to three (3) inches in length and thelower portion of the bracket extending from the center axis rod 119 tothe connecting rod bracket 206 is at least about two to three timeslonger than the upper portion. In a particular embodiment, the upperlinkage arm 112 is about 5.9 inches, the lower linkage arm 114 is about4.2 inches, the upper portion of the linkage arm bracket 125 is about1.8 inches and the lower portion of the linkage arm bracket 125 is about3.8 inches. In other embodiments, the lower linkage arm 114 is about thesame size or larger than the upper linkage arm 114. Generally, however,the upper portion of the linkage arm bracket 125 will be shorter thanthe linkage arm components, 112 and 114, although the invention is notso limited.

The clamping tower 142 and fence 116, as well as the stops 118 can alsobe made from metal, such as steel or aluminum, wood or plastic. Inembodiments in which the clamping tower 142 is secured to the fence 116the fence 116 should be made from a material capable of withstanding theforce provided by the clamping tower 142 during operation. The clampingtower 142 can also be of any suitable size and shape. In one embodiment,the clamping tower 142 is a substantially rectangular shape with aheight of sufficient dimension to accommodate the height of the clampassembly 110. In one embodiment, the clamping tower 142 has a height ofsufficient dimension to provide a suitable pivot point “D” for optimumperformance of the clamp assembly 110. In one embodiment, the clampingtower 142 has a height of about four (4) to seven (7) inches or more,depending on the size of the clamp assembly 110 and linkage arms 112 and114, as well as whether or not the clamping tower 142 is secured to thefence 116 or the worktable 101. In another embodiment, the clampingtower 142 has a height of about five (5) to six (6) inches. In oneembodiment, the clamping tower 142 has a width of sufficient dimensionto attach the clamp assembly 110 with the bracket 152 and a depth ofsufficient dimension to accommodate the pivot bracket 150, such as aboutone (1) to 2.5 inches. In a particular embodiment, the clamping tower142 has a height of about 5.4 inches, and a width and depth of about 1.5inches.

Other components, such as the guide block 126 are made from any suitablematerial. In one embodiment, the guide block 126 is a machined block ofaluminum of any desired size and shape, as long as the intended functioncan be performed. In one embodiment, the guide block 126 is arectangular piece of material about four (4) inches in length, six (6)inches in width and about 1.25 inches in height or thickness.

The handle 136, central axis rod 119, as well as the various brackets(e.g., 121, 125, 148, 152, 127 and 162) should also be made of materialshaving sufficient strength, such as metal such as aluminum or steel.Although wood or plastic can be used, components made from thesematerials are likely more bulky and/or expensive. The central axis rod119 can have any suitable diameter and length. In one embodiment, thecentral axis rod 119 has a diameter of about 0.25 to 0.75 inches and alength of about six (6) to 12 inches. The handle 136 can also be anysuitable size and shape. In one embodiment, the end of the handle 136nearest the hand grip 138 is elevated about 10 to 14 inches from theworktable 101 when in the off or home position, although the actuallength of the handle 136 may be greater if it has a bend, or is affixedto the handle bracket 137 at an angle as shown in FIG. 1. The hand grip138 can further be made of any suitable material which provides anadequate grip including all of the materials mentioned as well asceramics, rubber and the like.

The worktable 101 can also be made from any suitable material ormaterials, such as metal, wood or plastic, although wood or plasticsurfaces need to be sufficiently thick to accept the connectors used tomount components to the worktable 101. In one embodiment, the uppersurface 104 of the worktable 101 is made from at least two differenttypes of material (See FIG. 9). In one embodiment, the worktable 101 ismade from steel. In a particular embodiment, the worktable 101 is anapproximately “¼-inch” stamped steel plate about 13.5 inches in lengthand width. In an alternative the worktable 101 is machined aluminum,although this would be more expensive than steel. The worktable 101, aswell as the entire cabinet 102 can further be provided in multiplecomponents which are secured together by any suitable means (such as thecabinet 102 shown in FIGS. 3 and 4 in which a portion of the cabinet 102has been removed to provide a view of the components inside).

The various pivot pins can also be made from any suitable material. Inone embodiment, some or all of the pivot pins are steel clevis pins. Inanother embodiment, some or all of the pivot pins are threaded boltswith washers and nuts which are not tightened completely so as to allowindependent pivoting motion of the various components. Although use ofbolts, washers and nuts are more expensive, it allows a given pivotpoint to pivot with very little tolerance, thus providing a “sturdy”feel to the clamp assembly 110 as compared with a conventional pin, suchas a clevis pin. In one embodiment, bolts, washers and nuts are used atpivot points “B” and “D,” while clevis pins are used at pivot points “A”and lie,” although the invention is not so limited. As noted above, inanother embodiment, pivot point “D” is replaced with a fixed connection.

As shown in FIG. 5, the clamp assembly 110 is comprised of thecompression spring 170 surrounding a spring rod 504 having, in oneembodiment, a threaded end 505, the clamp pad 172, the clamp guide 174,the adjusting knob 176 having, in one embodiment, adjusting knob innerthreads 512, the fixed section 178 having, in one embodiment, fixedsection outer threads 510 and the locking knob 180 having, in oneembodiment, locking knob inner threads (not shown). As discussed herein,the compression spring 170 provides desired “give” in the clamp assembly110, thus providing the requisite adjustability for the clamp.Specifically, the compression spring 170, which is preloaded bythreading the clamp pad 172 onto the threaded end 505 prior to drilling,allows the clamp pad 172 to stop on the workpiece and maintain clampingpressure while the user is still continuing to pull on the handle 136 tocomplete the drilling cycle. Otherwise, once the clamp pad 172 contactsthe workpiece, the drilling cycle would stop and the drill would not yethave drilled the pocket hole.

The compression spring 170 also allows a wide range of materialthicknesses to be accommodated with any given position of the clampassembly 110. In one embodiment, the compression spring 170 allows foradjustments of up to about “ 1/16-inch” in material thickness eitherway, for a total range of about “⅛-inch” in adjustments with any givenclamp assembly position. In other embodiments, up to “¼-inch” or more ofadjustability is provided. However, with adjustment levels in thisrange, the timing of the drill movement would need to be altered, i.e.,slowed, to avoid having the drill bit 109 contact the workpiece beforethe clamp pad 172 does. Such adjustments can be made by adjusting theratio of movement of the clamp assembly 110 and drill 108, which caninclude adding slack to delay the movement of the drill 108, asdiscussed below. This ability to adjust is unlike a toggle clamp whichprovides no range of adjustability at any given position of the clampassembly 110. Additionally, as there is no “locking mechanism” on theclamp assembly 110 to lock the clamp pad 172 into position, the clamppad 172 is essentially “locked” in place by the user when he continuesto pull on the arm 136, thus allowing a one-step drilling operation.This is unlike conventional machines in which a conventional clamp, suchas a toggle clamp, is used in one step to clamp the workpiece and amechanical arm is used in a separate second step to activate only thedrill.

The compression spring 170 is preferably a helical compression spring ora die spring made from steel and capable of withstanding between about150 and 300 lb_(f) with about 0.25 to 0.75 inches of deflection. In oneembodiment, the compression spring 170 provides up to about 0.5 inchesof displacement to the clamp assembly 110. In one embodiment, about 0.25inches of displacement is provided. In one embodiment, the compressionspring 170 is capable of with standing up to about 300 lb_(f) or more atabout 0.33 to 0.5 inches of deflection. In one embodiment, the spring isbetween one (1) and four (4) inches in length and about 0.5 and one (1)inches in diameter. In a particular embodiment a die spring made byDanly IEM, having offices in Cleveland, Ohio, is used. In a particularembodiment, the spring is a Danly DieMax XL spring model no. 9-1206-26which is about 0.75 inches in diameter, about 1.5 inches in length,capable of withstanding up to about 295.2 lb_(f) with a maximumdeflection of approximately 0.45 inches. The spring rod 504 can be anyrod around which the compression spring 170 is wound. In thisembodiment, the spring rod 504 is a bolt with a threaded portion 505 asshown, such as an approximately 0.3 inch diameter bolt with the threadedportion 505 having a length of about 0.3 to 0.5 inches.

FIGS. 6-8 show the range of motion of the various components throughouta drilling cycle. FIG. 6 is in “POSITION 1” which is at the beginning ofa drilling cycle and is also likely the position in which the unit isstored. As can be seen, the handle 136, having a handle centerline 601,is in an up or home position, i.e., any suitable position which allowsthe switch 202 to be in an off position (i.e., in this embodiment, incontact with the tab 208). In one embodiment, when the handle 136 is inthe home position, the upper end of the handle 136 is at a verticaldistance of about 10 to 14 inches from the worktable 101. The upper andlower linkages, 112 and 114, respectively, having centerlines 606 and608, respectively, are also in their home positions in FIG. 6, such thatthe clamp assembly 110 is at its maximum distance from the worktable101. In this position, distance 604 is about 0.75 to 1.65 inches. Aworkpiece 650 placed under the clamp assembly 110 has a maximum height652 of about 0.75 inches in most embodiments, but can range from about0.5 to 1.5 inches in height. In most embodiments, the “gap” (i.e.,distance 660) between the bottom of the clamp pad 172 and the top of theworkpiece 650 prior to drilling is about 0.01 to 0.18 inches, up toabout 0.2 inches. In one embodiment, distance 660 is about “118-inch.”Preferably the distance 660 is sufficiently large to allow the workpiece650 to be inserted and removed. However; if distance 660 is too largethe drill bit 109 will contact the workpiece 650 before it is fullyclamped. The compression spring 170 is also subject to its minimum loadat this point, having only the preload created when the clamp pad 172 isthreaded onto the spring rod 506, such that distance 605 is at itsmaximum. In one embodiment distance 605 is between about 0.2 to 0.3inches when the clamp assembly 110 is in an unclamped position as inFIG. 6. It is important that a sufficient amount of preload is used toprevent the drill bit from twisting the workpiece during operation. Inone embodiment, a reload of between about 125 lb_(f) and 175 lb_(f) isused. In a particular embodiment, about 150 lb_(f) is used.

The various components can be positioned at different angles withrespect to the worktable 101 when in their home or off position,depending on their length, size of the clamp assembly 110, size of theclamping tower 112, and so forth. In one embodiment, angle 602 betweenthe handle centerline 601 and the worktable 101 is between about 52 and72 degrees. In one embodiment, angle 612 between the upper linkagecenterline 606 and the worktable 101 is about five (5) to 15 degrees. Inone embodiment, angle 614 between the lower linkage centerline 608 andthe worktable 101 is about 91 to 101 degrees. In this embodiment, angle616 between a linkage arm bracket centerline 617 and the worktable 101is about 35 to 45 degrees. In this embodiment, angle 620 between theupper and lower linkage centerlines, 606 and 608, respectively, is about100 to 120 degrees. In this embodiment, angle 622 between the upperlinkage 112 and clamp assembly centerline 619 is about 67 to 87 degrees.In one embodiment angle 602 is about 62 degrees, angle 612 is about ten(10) degrees, angle 614 is about 96 degrees, angle 616 is about 40degrees, angle 620 is about 110 degrees and angle 622 is about 77degrees.

FIG. 7 is in “POSITION 2,” which is after the user has pulled the handle136 down such that a first contact with the workpiece 650 has occurredalthough the compression spring 170 is still at its minimum load, suchthat distance 605 remains the same as in FIG. 6. At this point in timethe tab 208 is now no longer in contact with the switch 202 such thatthe motor 160 (not shown) has started. Additionally, although thecompression spring 170 is still at its minimum load, the clamp assembly110 has moved downwardly such that distance 604 has been reduced byabout 0.01 to 0.1 inches (i.e., by the amount of distance 660) such thatdistance 604 is now the same as distance 652, i.e., the height of theworkpiece 650. Additionally, the various angles between the componentshave changed. In one embodiment, angle 602 between the handle 136 andthe worktable 101 is now about 55 to 60 degrees. In one embodiment,angle 612 between the upper linkage centerline 606 and the worktable 101is now about three (3) to 13 degrees. In one embodiment, angle 614between the lower linkage centerline 608 and the worktable 101 is about87 to 97 degrees. In this embodiment, the angle 616 between the linkagearm bracket centerline 617 and the worktable 101 is about 47 to 57degrees. In this embodiment, angle 620 between the upper and lowerlinkage centerlines, 606 and 608, respectively, is about 90 to 110degrees. In this embodiment, angle 622 between the upper linkage 112 andclamp assembly centerline 619 is between about 72 to 92 degrees. In oneembodiment angle 602 is about 57.5 degrees, angle 612 is about eight (8)degrees, angle 614 is about 92 degrees, angle 616 is about 52 degrees,angle 620 is about 100 degrees and angle 622 is about 82 degrees.

FIG. 8 shows the various components in “POSITION 3,” which is after theuser has pulled down the handle 136 a maximum distance, i.e., to anangle of about 45 degrees from the worktable 101 (although the inventionis not so limited), and the drilling operation has just completed. Thetab 208 remains pulled away from the switch 202 such that the motor 160(not shown) is still running. At this point the compression spring 170in the clamp assembly 110 is at its maximum compression and the variousangles between the components have further changed. In one embodiment,angle 602 between the handle 136 and the worktable 101 is now about 35to 40 degrees. In one embodiment, angle 612 between the upper linkagecenterline 606 and the worktable 101 is now about zero (0) to ten (10)degrees. In one embodiment, angle 614 between the lower linkagecenterline 408 and the worktable 101 is now about 78 to 88 degrees. Inthis embodiment, angle 616 between the linkage arm bracket centerline617 and the worktable 101 is about 70 to 80 degrees. In this embodiment,angle 620 between the upper and lower linkage centerlines, 606 and 608,respectively, is about 76 to 96 degrees. In this embodiment, angle 622between the upper linkage 112 and clamp assembly centerline 619 isbetween about 76 to 96 degrees. In one embodiment angle 602 is about37.5 degrees, angle 612 is about five (5) degrees, angle 614 is about 83degrees, angle 616 is about 75 degrees, angle 620 is about 86 degreesand angle 622 is about 86 degrees.

At this point in time, the user would push up on the handle 136 causingthe components to return to the home position shown in FIG. 6, which inturn causes the motor 160 (not shown) to turn off due to the breaking ofthe circuit in the switch 202, which, in this embodiment, is caused bythe tab 208 again contacting the switch 202.

As long as the clamp assembly 110 is holding the workpiece 650 in placeduring the entire drilling operation, the ratio of the movement of theclamp assembly 110 and drill 108 can vary widely. In one embodiment,such as the embodiment described in FIGS. 6-8, pulling the handle 136forward to an angle of approximately 45 degrees with the worktable 101causes the clamp assembly 110 and drill 108 to move in a ratio of about1:6. In another embodiment, the ratio is less than 1:6 down to about 1:1and in yet other embodiments the ratio is greater than 1:6 up to about1:10. With a ratio of about 1:1, the handle 136 would likely be longerthan with a higher ratio (as handle length affects the amount of travelin the clamp assembly 110) and distance 604 would be much greater thanshown in FIG. 6. In most embodiments, the drill 108 begins its forwardmovement at substantially the same time the clamp assembly 110 beginsmoving, but the timing is such that the clamp pad 172 contacts theworkpiece 650 before the drill bit 109 does. (In some instances it maybe necessary to make adjustments in timing of drill movement to ensurethe clamp contacts the workpiece prior to the drill bit. For example,additional slack can be created in movement of the drill 108, such aswith a chain linkage between the linkage arm bracket 125 and theconnecting rod bracket 206). Once the clamp pad 172 contacts theworkpiece 650, it stops moving while the rest of the clamp assembly 110continues to compress the compression spring 170 further until drillingis complete. In embodiments which use a stop collar 166, drilling iscomplete when the stop collar 166 contacts the guide bushing 128, thuspreventing any further advancement of the clamp assembly 110 and drillbit 109.

In one embodiment, the clamp assembly 110 travels about 0.25 inches(distance 660) while the drill 108 travels about two (2) inches, suchthat the ratio of travel between the clamp assembly 110 and the drill108 is about 1:8. Changing distance 660, will change the ratio of themovement of the clamp assembly 110 and drill 108. It is also importantto note that the movement of the clamp assembly 110, not including theclamp pad 172, will always be constant regardless of the type ofcompression spring 170 used. However, the movement of the clamp pad 172in relation to the drill 108 is dependent on the type of compressionspring 170 used. In fact, use of other types and sizes of compressionsprings 170 can cause this ratio to vary between about 1:4 up to 1:10.The higher the ratio, the more force is applied to the workpiece 650 bythe clamp assembly 110 at the beginning of a drilling operation. It isparticularly important to have a sufficient amount of force at thebeginning of the drilling operation as the drill 108 starts to enter theworkpiece 650 because the drill bit 109 has a tendency to move theworkpiece 650 as it rotates and contacts the workpiece 650. Once thedrill bit 109 has entered the workpiece 650 this tendency is lessened.However, the device described herein allows sufficient clamping force tobe maintained on the workpiece 650 throughout the drilling operation.

In most embodiments, components are sized appropriately to provideoptimum clamping pressure during all phases of the drilling cycle, withleast resistance to the user. In a particular embodiment, thecompression spring 170 is about 1.5 inches in length, and compressed toabout 1.25 inches in length prior to beginning the drilling operation,thus giving the compression spring 170 (and therefore the clamp assembly110) a preload of about 164 lb_(f). As the drilling operation progressesand the clamp assembly 110 bears down on the workpiece 650, thecompression spring 170 travels, in one embodiment, another 0.25 inches,for a total of about 0.5 inches total deflection, providing a load ofabout 328 lb_(f), although, again, the invention is not so limited. Itis important to note that the shorter the distance the compressionspring 170 needs to travel, the less force is required by the user tooperate the device 100.

FIG. 9 shows a simplified perspective view of a pocket hole drillingmachine 100 in one embodiment of the present invention. In thisembodiment, the entire cabinet 102 can be seen as described herein. Sucha unit, having, in one embodiment, a height of between about six (6) andeight (8) inches, is useful for placement on a table or work surface,although, as noted above, the unit can be made as a floor model, and, insome embodiments, can include legs. The machine 100 shown in FIG. 9 hasthe handle 136 in the up or “1” position, such that the clamp pad 172 isnot in contact with the workpiece 902. Once the handle 136 is pulled inthe downwardly direction, as indicated, the clamp pad 172 will move downtowards to contact the workpiece 902 as the drill 108 moves forward,allowing the drill bit 109 to then make contact with and ultimatelydrill a hole in the workpiece 902. The clamp pad 172 is then releasedwhen the user pushes the handle 136 back up into the position shown.FIG. 9 also shows an alternative stop 918 which can be used, although,again, the invention is not so limited. Any suitable type of stop can beused. The worktable 101 in this embodiment is divided into two sections,904 and 906, each made from a separate type of material. In oneembodiment, 904 is any type of steel or aluminum and 906 is differenttype of steel or aluminum or any type of rubber, wood or plastic. In aparticular embodiment, section 904 is made from zinc plated mild steeland section 906 is made from an acrylic material.

Referring again to FIGS. 1 and 6-8, in use, a user grabs the hand grip138 and starts pulling the handle 136 towards himself in a downwardlydirection. This causes the upper and lower linkage arms, 112 and 114,respectively, to move up and toward the user, allowing the clampassembly 110 to move down on top of a workpiece 650 as discussed herein.Completing the pull of the handle 136 sends appropriate clampingpressure down on the workpiece 650, such as about 200 to 300 lb_(f) asdiscussed, holding it securely to the worktable 101. Although higherclamping pressures could be used, pressures greatly in excess of 300lb_(f) likely could become excessive and only increase the work for theuser. This action simultaneously pulls the drill 108 via the connectingrod 120 along the guide rods 124 sending the drill bit 109 up throughthe drill bit opening 106 (and optionally through a guide bushing 128)and into the workpiece 650.

Embodiments of the invention further comprise a method comprisingactivating an adjustable clamp assembly and a remote drill switchsubstantially simultaneously by pulling a handle connected to theadjustable clamp assembly and the remote drill switch in a downwardlydirection, wherein clamping and drilling are completed in one stepwithout the use of compressed air. In one embodiment, the method furthercomprises drilling a hole in a workpiece with a drill connected to theremote drill switch, the drill having a drill bit connected thereto. Inone embodiment, the method further comprises pushing the handle in anupwardly direction after the hole has been drilled. In most embodiments,the drill and adjustable clamp assembly start moving at about the sametime. The drill switch is in off when the handle is in a first position.The drill switch is on when the handle is in either a lower secondposition or an even lower third position.

The semi-automatic system described herein provides a user, for thefirst time, with the ability to clamp and drill in a single step withoutthe need for any compressed air, i.e., a non-pneumatic system. Thecompression spring within the adjustable clamp provides versatility inthe thicknesses of boards which can be drilled at a given clamp setting,although adjustments to the length of the clamp can easily be made withan adjusting knob. The movement of the drill in relation to the handlecan further be adjusted to provide for varying ratios of movement. Thisprovides for even greater differences in material thicknesses which canbe used without the need to adjust the clamp. However, some adjustmentsin timing of drill movement to ensure the clamp contacts the workpieceprior to the drill bit may be necessary as discussed herein. The resultis a precision drilled hole made quickly, conveniently and economically.

Although specific embodiments have been illustrated and describedherein, it will be appreciated by those of ordinary skill in the artthat any arrangement that is calculated to achieve the same purpose maybe substituted for the specific embodiment shown. For example, thesystems and methods described herein could also be used to drill othertypes of holes such as dowel holes. Additionally, the machine describedherein could be altered for use as a line boring machine, or even as asawing machine, by replacing the drill with a suitably-sized saw. Thisapplication is intended to cover any adaptations or variations of thepresent subject matter. Therefore, it is manifestly intended thatembodiments of this invention be limited only by the claims and theequivalents thereof.

1. A non-pneumatic system for use with a workpiece comprising: a cabinethaving a work surface; a clamp assembly secured to the cabinet, theclamp assembly including a clamp pad positioned above the work surface;an electrically operated tool positioned below the work surface andhaving a remote switch which when activated is operatively configured toactivate the tool; and a lever operatively coupled to the clamp assemblyand the tool and operatively configured to simultaneously activate theremote switch and to move the clamp pad down towards the work surface bymanually moving the lever.
 2. The system of claim 1 wherein the tool ismovably secured to the cabinet and the lever is operatively configuredto move the tool towards an opening in the work surface by manuallymoving the lever.
 3. The system of claim 1 further comprising a tab on alinkage arm operatively coupled to the lever and positioned such thatthe tab removes contact with the remote switch when the lever ismanually moved whereby the remote switch is activated.
 4. The system ofclaim 1 wherein the tool comprises one of a drill and a saw.
 5. Thesystem of claim 1 having the workpiece positioned on the work surfacewherein the lever is operatively configured to move from a firstposition to a second position when manually moved, the first positioncomprises the clamp pad not being in contact with the workpiece and theremote switch being off, and the second position comprises the clamp padbeing in contact with the workpiece and the remote switch being turnedon before the lever reaches the second position.
 6. A non-pneumaticsystem for use with a workpiece comprising: a cabinet having a worksurface with an opening; an electrically operated tool movably securedto the cabinet and positioned below the work surface, the tool having aremote switch which when activated is operatively configured to activatethe tool; and a lever operatively coupled to the tool and operativelyconfigured to simultaneously activate the remote switch and to move thetool up towards the work surface opening by manually moving the lever.7. The system of claim 6 further comprising a clamp assembly secured tothe cabinet, the clamp assembly including a clamp pad positioned abovethe work surface, wherein the lever is operatively configured to movethe clamp pad down towards the work surface by manually moving thelever.
 8. The system of claim 6 further comprising a tab on a linkagearm operatively coupled to the lever and positioned such that the tabremoves contact with the remote switch when the lever is manually movedwhereby the remote switch is activated.
 9. The system of claim 6 whereinthe tool comprises one of a drill and a saw.
 10. A non-pneumatic systemfor use with a workpiece comprising: a cabinet having a work surfacewith an opening; a clamp assembly secured to the cabinet, the clampassembly including a clamp pad positioned above the work surface; anelectrically operated tool movably secured to the cabinet and positionedbelow the work surface, the tool having a remote switch which whenactivated is operatively configured to activate the tool; and a leveroperatively coupled to the clamp assembly and the tool and operativelyconfigured to simultaneously activate the remote switch and to move theclamp pad down towards the work surface and the tool up towards the worksurface opening by manually moving the lever.
 11. The system of claim 10wherein the clamp assembly is pivotally connected to the tool.
 12. Thesystem of claim 10 wherein the clamp assembly, tool and lever are eachconnected to a central axis rod, the clamp assembly being pivotallyconnected to the central axis rod with a linkage arm, and the tool beingpivotally connected to the central axis rod with a connector.
 13. Thesystem of claim 12 wherein the clamp assembly linkage arm comprisesfirst and second linkage arms, the first linkage arm is pivotallycoupled to the central axis rod at one end and pivotally connected tothe second linkage arm at an opposing end, and the second linkage arm ispivotally coupled to the clamp pad.
 14. The system of claim 10 furthercomprising a tab on a linkage arm operatively coupled to the lever andpositioned such that the tab removes contact with the remote switch whenthe lever is manually moved whereby the remote switch is activated. 15.The system of claim 10 wherein the tool comprises a drill.
 16. Thesystem of claim 15 wherein the drill comprises a collet operativelyconfigured to accept and hold a drill bit having a longitudinal axisthat intersects the opening and wherein the lever is operatively coupledto the drill to move the drill collet along the longitudinal axis bymanually moving the lever.
 17. The system of claim 16 further comprisinga guide rod operatively coupled to the drill and to a guide blocksecured beneath the work surface, the guide rod being operativelyconfigured to guide the drill collet along the longitudinal axis uponmovement of the lever.
 18. The system of claim 10 wherein the toolcomprises a saw.
 19. The system of claim 10 wherein the lever comprisesa handle.
 20. The system of claim 10 having the workpiece positioned onthe work surface wherein the lever is operatively configured to movefrom a first position to a second position when manually moved, thefirst position comprises the clamp pad not being in contact with theworkpiece and the remote switch being off, and the second positioncomprises the clamp pad being in contact with the workpiece and theremote switch being turned on before the lever reaches the secondposition whereby the workpiece can be clamped and drilled in one step bymoving the lever from the first to the second position.